Method and apparatus for making wall panels

ABSTRACT

Disclosed method and apparatus continuously forms building wall panels using pre-formed sub-assemblies having centrally positioned locators thereon. Locating notches are formed in the top and bottom frame plate members at the centers for various window, door and post components. The plate members are fed continuously and as the locators drop into the notches, thereby properly locating the sub-assemblies, they are carried to a nailing station where they are fastened to the plate members.

United States Patent Frydenberg [4 Oct. 24, 1972 [54] METHOD ANDAPPARATUS FOR MAKING WALL PANELS [72] Inventor: Donald V. Frydenberg,Arlington,

Tex.

[73] Assignee: Clary Corporation, San Gabriel,

Calif.

[22] Filed: May 3, 1971 [21] Appl. No.: 139,731

[52] US. Cl. ..29/155 R, 29/200 B, 29/469 [51] Int. Cl. ....B23p 17/00,B23p 19/00, B23p 21/00 [58] Field of Search ..29/ 155 R, 200 B, 200 A,469

Bowers, Jr ..29/200 B Rosenblo'm ..29/4 1 7 Primary ExaminerThomas H.Eager Att0rney--Fred N. Schwend [57] ABSTRACT 7 post components. Theplate members are fed continuously and as the locators drop into thenotches, thereby properly locating the sub-assemblies, they are [56]References Cited carried to a nailing station 'where they are fastenedto UNITED STATES PATENTS the plate members. 7

3,413,703 12/1968 Sanford 155 14 Claims, 15 Drawing Figures LI 1 l H HPATENTEDHB 24 1972 SHEET 1 OF 4 P'A'TENTEDHEI 1912 3,699,622

SHEET 2 OF 4 I N VEN TOR. Domw V. FQYDENBEPG /l/z /4J PATENTEUum 24 I972SHEET 3 BF 4 IN VENTOR, 00mm V fbvacwsms PATENTEDIJBI 24 I972 SHEET l 0F4 INVENTOR;

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. 1 METHOD AND APPARATUS FOR MAKING WALL PANELS BACKGROUND OF THEINVENTION 1. Field of the Invention This invention relates to a methodand apparatus for pre-fabricating wall panels for buildings.

2. Description of the Prior Art Wall panels have been pre-fabricatedheretofore using conveyor systems wherein spaced top and bottom platemembers are intermittantly advanced endwise along an assembly table fromone station to the next. Differentstructural members such as studs,sheathing, etc., are secured at. different stations while the partiallycompleted wall panel remains stationary at such stations.

In some'cases, the plate members are notched beforehand, as disclosed,for example, in the US. Pat. to Bamford No. 2,574,163, to receive theends of the various through studs and other studs forming parts of thewindow and door sub-assemblies. In other cases, the cations of suchstuds are marked on the plate members by pencil or the like. In eithercase, such locations for the studs forming part of sub-assemblies aredetermined based on an architects drawing which generally shows only thedimensions from an outside wall to the centers of the windows and doors,or to the centers of any inside walls.

The locations of the studs forming part of such subassemblies are thencalculated so that they will be located equal distances from the centersand are marked off on the plate members. Later, at one of the stations,the studs are located in their proper marked positions and are nailed tothe plate members to form a skelton wall panel, after which, atsubsequent stations, the sheathing and other components are secured tothe wall panel.

Although such methods of assembly are satisfactory, they are often timeconsuming and confusing to the workmen, particularly because thewindow'and door subassemblies are usually of different widths.Therefore, the studs forming part of such sub-assemblies must be spaceddifferent and equal distancesfrom the subassembly centers as set forthin the architects drawings. Also, any wall junction posts and similarsubassemblies must be located on opposite sides of center locationsfound in the drawings. This requires the workman to determine not onlythe distance from the center of a window, door, or the like to its sideends but also to add an additional amount for clearance, etc., dependingon the particular type of window or door to be installed. For example, ametal window generally requires a different spacing between its sidesand the adjacent window sub-assembly forming studs than does a woodendoor. Also, the centers of the various through studs must be accuratelylaid off at normally 16 inch centers.

SUMMARY OF THE INVENTION According to the present invention varioussub-assemblies, i.e., window opening frames, door opening frames, cornerposts, wall junction posts, etc., are preassembled. Locating means arefonned on the plate members in the form ofnotches located only at thecenters for the various sub-assemblies or sub-assembly frames, and asthe plate members are fed along the assembly table, appropriate ones ofthe pre-assembled sub-assemblies having locating elements at the centersthereof are laid along the plate members and as the sub-assembliesbecome properly lined up relative to the wall panel being formed, thelocating elements drop into the notches to accurately locate thesub-assemblies in position and to carry them to a nailing station readyto be nailed in place. At such nailing station, the sub-assemblies arenailed to the plate members. Also the through studs are located on 16inch centers, wherever the spacing between the sub-assemblies permits,and are also nailed in place.

Such arrangement enables the plate members and resulting wall panel tobe moved at a continuous rate of speed along the assembly table. It alsoreduces the complexity of assemblying the wall panels, enables a greaterspeed of assembly, reduces the amount of assembly labor and greatlyreduces the possibility of error in properly locating the variouscomponents of such' wall panels.

I BRIEF DESCRIPTION OF THE DRAWINGS.

FIG. 2 is a portion of an architects drawing appropriate forthe wallpanel section of FIG. 1.

FIG. 3 is a perspective view of a window sub-assembly with locatorsattached thereto.

FIG. 4 is a perspective view of a wall junction post sub-assembly withlocators attached thereto.

FIG. 5 is fragmentary plan view of a plate member and part of asub-assembly frame located in proper relative positions by means of thepresent invention. I

FIG. 6 is sectional view taken along line 6-6 of F IG. 5. I

FIG. 7 is a plan view of part of an assembly apparatus constructedaccording to the present invention.

FIG. 8 is a plan view of part of a frame plate member marked to indicatethe centers. of various sub-assemblies.

FIG. 9 is a side view showing the subassembly placement station.

. FIG. 10 is a sectional view illustrating the plate notching mechanismand is taken along the line 10--10 of FIG. 7.

FIG. 11 is a sectional view taken substantially along the line 11-11ofFIG. 7.

FIG. 12 is a sectional view taken along line l2-l2 of FIG. 7,illustrating the nailing station.

FIG. 13 is a sectional view taken along the line 13- 13 of FIG. 12.

FIG. 14 is a sectional view taken along the line 14- 14 of FIG. 7.

FIG. 15 is a sectional view taken along line l5-15 of FIG. 14.

DETAILED DESCRIPTION OF PREFERRED METHOD AND APPARATUS FIG. 1illustrates a partially completed or skeleton frame 11 of a wall panelfabricated according to the present invention. The skeleton comprisestop and bottom plate members 12 and 13, respectively, a door subassembly14, a window sub-assembly 15, a wall juncture post sub-assembly 16, andcorner post sub-assembly 17, all suitably nailed at their ends to theplate members.

Through studs, i.e., 18, are shown nailed to the plate members on16-inch centers. However, the distance between a through stud and theouter stud of an adjacent sub-assembly may vary depending on thedistance between adjacent sub-assemblies, although such spacingshould'normally be 16 inches or less.

The skeleton frame 11 may form either a complete wall panel of abuilding or a modular unit which is later secured to other units ofsimilar or different lengths to form a complete wall panel.

FIG. 2 shows part of an architects drawing wherein the wall panel 11 ofFIG. 1 is depicted at 11a to be an outside wall including a door 14a, awindow 15a, an inner wall 20 and an adjoining outside wall 21. It willbe noted that the drawing indicates only the dimensions from the outsideedge of an outside wall panel to the centers of the windows, doors, andinterior walls. Window and door schedules or lists (not shown) are alsogenerally provided on the drawing which indicate the type and nominalsizes of the windows and doors from which are determined the spacing ofthe various sub-assembly studs, i.e., 23 and 24, defining the openingsfor such windows and doors.

In accordance with the present invention the various sub-assemblies,i.e., 14, 15 16 and 17 are pre-assembled. FIG. 3 illustrates a windowsub-assembly comprising outside studs 25, inside studs 26, header 27,still 28 and cripples 29, all formed generally of 2 X 4 -inch memberssecurely nailed together.

Also, in accordance with the invention, locators 33 are securely mountedon the top and bottom ends of each sub-assembly and these are locatedexactly midway between the side ends, i.e., between the outer studs 25in FIG. 3. As shown in FIGS. and 6, each such locator comprises a thinsemi-cylindrical metal or plastic body 34 and an integral semi-circularflange 35, the latter having nail holes 36 formed therein. The body 34has a length approximately equal to one half the thickness of each platemember.

In order to secure the locators 33 in proper position at the ends of thesub-assemblies, and to facilitate fabrication and handling of the subassemblies, each locator is nailed or otherwise fastened to a wooden l X4 -inch member 37 which is, in turn, secured by nails 39 to the end ofthe sub-assembly. As shown in FIG. 6, the upper edge of the locator 33is located flush with the upper edge of the member 37 so that the axisof the locator lies coincident with the plane of the adjacent face ofthe sub-assembly. FIG. 4 illustrates a wall junction post sub-assemblycomprising three2 X 4 -inch members 38, 39, and 40 nailed together andhaving locators 33 secured thereto by short lengths of l X 4 -inchmembers 41. Here, also, the locators are located exactly midway betweenthe outer edges of the members 38 and 40.

Referring to FIGS. 7 to 15, and to FIG. 11 in particular, the wall panelassembling apparatus comprises a table formed of angle guide members 42and 43 supported in spaced relation to each other by structural sideframe members 44 and 49, respectively.

Spaced endless chains 45, FIGS. 14 and 15, are driven along a portion ofthe table, over sprockets 46,

and along side the guide members 42 and 43. The sprockets are carried byshafts, 47 and 147, the latter being driven by a continuously runningmotor 48. Such chains have drive spurs 50 extending-from certain of thelinks thereof whichengage the undersides of the plate members 12 and 13to positively drive the latter in concert with each other along thetable. Rollers 51, 52 and 53 are rotatably mounted on guide framemembers 59 secured to the frame members 44 and 49, and are located abovethe lefthand sprockets 46 at progressively shorter distances above thetable so that they may progressively impale the plate members to greaterextents upon the drive spurs 50.

As the trailing end of each plate member, i.e., 12, approaches the drivechain 45 a new plate member, i.e., 12a, is fed in abutment therewith soas to form a continuous length plate member.

Splicing devices generally indicated at 55 and 56 are located over theplate members at a splicing station 49 to permanently splice theabutting ends of separate plate members while the latter arecontinuously advanced over the table. Since such splicing devices do notform the subject matter of the present invention, they are not disclosedin detail herein. Thereafter, marks, i.e., 47, FIG. 8, are preferablyapplied to the plate members by crayons or the like to indicate theplacement of the various sub-assemblies. This may be done automaticallyby means, not shown, or manually by reference to pre-marked measuringtapes, not shown, which are laid along the plate members and markedaccording to dimensions on the architechs drawings. Thereafter, theplate members pass through a notching station 58' where semi-circularnotches 60, FIG. 10 and 11, are formed in the plate members, coincidentwith the marks 57. Such notches are substantially of the same radii asthe outside radii of locators 33.

The notching device comprises a pair or rotating cu'tters 62 and 63carried at the outer ends of a shaft 64 which is continuously driven bya motor 65. The shaft 64 is rotatably supported in bearings carried byarms 66 and 67 which, in turn, are carried by a rock shaft 68 journaledin bearing brackets 70, the shaft 68 being secured to an arm 71 which isconnected to the piston rod of an air cylinder 72 anchored to a crossframe member 73. The motor 65 is attached to a cross brace 74 securedbetween the arms 66 and 67.

The air cylinder 72 is suitably actuated as the marks 57 pass under thecutters 62 and 63 to form the notches 60 with the centers thereofcoincident with such marks. Control of the cylinder 72 may beaccomplished under manual control by valve means, not shown, or byphotoelectric control means, now shown but well known in the art. Itwill be noted that the notches are cut to depths equal to one half thediameters of the cutters 62 and 63.

Subsequent to the notching operation, the plate members are fed througha sub-assembly placement station 75 (see also FIG. 9) where variousprefabricated sub-assemblies, i.e., 15, as determined by the nominalsizes found in drawings, are placed, one at a time, between the platemembers 12 and 13 with the locators 33 resting on the upper edges of theplate members. Locating dogs 76 are pivotally supported at 77 and areheld by springs 78 in positions to yieldably maintain a sub-assembly ina fixed position as the plate members move thereunder. When the notches60 in the plate members become aligned with the locators the latter dropinto the notches, thereby locating the subassemblies in properpositions. The dogs 76 now yield as the sub-assemblies are carried bythe plate members toward a nailing station 80.

As shown particularly in FIG. 7, l2, and 13, endless conveyor chains 81and 82 are supported by sprockets 83 at opposite ends thereof to movealong the under edges of the plate members in the vicinity of thenailing station 80. The sprockets 83 ahead of the nailing station 80 arecarried by a shaft 84 which is driven by the motor 48 through an endlesschain drive 84 so as to move the chains 81 and 82 in concert with theplate members.

Each of the chains 81 nd 82 carries stud locating devices generallyindicated at 86 which are spaced apart on 16-inch centers. The devices86 each comprises a bracket 87 suitably secured to a link of itsrespective chain and is pivotally connected at 88 to a U-shaped dog 90adapted to embrace an adjacent end of a through stud, i.e., 18. Atorsion spring 91 normally holds the dog 90 in its upper illustratedposition. Various through studs are fitted over the locating dogs 90prior to passage through the nailing station. This may be accomplishedmanually or by suitable automatic handling mechanism, not shown. Inthose cases where a sub-assembly passes over a dog 90 it will lower thedog into, an ineffective position against the action of its spring 91.

Nailing devices generally indicated at 92 are suitably supported at thenailing station 80 adjacent plate members 12 and 13 to nail such platemembers to the various through studs and sub-assemblies as they passthrough the nailing station to form the skeleton wall panel. Suchnailing devices are well known in the art. Nailing devices of thisnature may be commercially obtained, for example, from the .PaslodeCompany, Skokie, Illinois and may be actuated either manually at anappropriate time as each through stud or stud of a sub-assembly passesthe same or they may be actuated automatically under control of suitablesensing device, not shown, which sense the passage of the studs andsub-assemblies past the nailing devices.

In a subsequent station, now shown, sheathing and other components arefastened to the various assembled plate members, studs, andsub-assemblies to form the completed wall panel. Thereafter, travelingcut-off saws, not shown, cut the continuous wall panel thus formed intocomplete wall panels or into modular wall panel sections which may belater assembled together to form a complete wall panel.

I claim: frame extending between said said plate 1. The method offorming a building wall panel having spaced plate members, at least onesub-assembly frame extending between said plate members, and throughstuds extending between said plate members which comprises forming saidsub-assembly frame,

forming first locating means on at least one of the top and bottom endsof said frame and centrally of the I side ends of said frame,

forming second locating means on at least one of said plate members atthe center for said frame,

placing said frame intermediate said plate members,

moving said plate members endwise relative to said frame whereby tocause said first locating means to engage said second locating means,

thereafter fastening said frame to said plate mem- 5 bers, and fasteningsaid studs to said plate members.

2. The method according to claim 1 comprising forming said firstlocating means on both said top and bottom ends of said frame andforming said second locating means on both of said plate members.

3. The method of forming a building wall panel having spaced platemembers, at least one sub-assembly frame extending between said platemembers, and through studs extending between said plate members whichcomprises forming said subasseinbly frame,

forming first locating means on. the top and bottom ends of said frameand centrally of the side ends of said frame,

forming second locating means on said plate members at the center forsaid frame,

placing said frame intermediate said plate members,

moving said plate members endwise relative to said frame whereby tocause said first locating means to engage said second locating means andto move said frame to a fastening station, and

fastening said frame and said studs to said plate members at saidfastening station.

4. The method according to claim 3 comprising moving said plate membersendwise at a continuous rate of speed.

5. The method of forming a building wall panel having spaced plate.members,

at least one sub-assembly frame extending between said plate members,

and through studs extending between said plate members which comprisespre-forming'said subassembly frame,

forming outwardly extending locating elements on the top and bottom endsof said frame and centrally of the side ends of said frame,

forming locating notches in said plate member at the center for saidframe,

placing said frame intermediate said plate members with said locatingelement resting on said plate members under the influence of gravity,

moving said plate members endwise relative to said frame whereby toenable said locating elements to drop into said locating notches and tocause said plate members to move said frame to a fastening station,

and fastening said frame and said studs to said plate members at saidfastening station.

6. The method forming a building wall panel having spaced plate members,

at least one sub-assembly frame extending between said plate members,and through studs extending between said plate members which comprisespreforming said sub-assembly frame, forming outwardly and co-axiallyextending semicylindrical locating elements on the top and bottom endsof said frame with the axes of said elements extending midway betweenthe side ends of said frame,

forming co-axially extending semi-cylindrical notches in said platemembers with the axes of said notches extending coincident with thecenter for said frame,

placing said frame intermediate said plate members with said locatingelements resting on said plate members under the influence of gravity,

moving said plate members endwise relative to said frame whereby toenable said locating elements to drop into said notches and to cam saidplate move said frame to a fastening station,

spacing said studs along said plate members,

and fastening said frame and said studs to said plate members at saidfastening station.

7. Apparatus for forming a building wall panel having spaced platemembers,

at least one sub-assembly frame extending between said plate members andthrough studs extending between said plate members which comprises meansfor moving said plate members endwise successively through a pluralityof stations,

means at one of said stations for forming a locating formation on atleast one of said plate members,

said locating formation being located at the center for said frame,

means at a subsequent station for yieldably maintaining said framestationary intermediate said plate members,

said frame having at least one locating element extending therefromcentrally of the side ends of said frame,

said locating formation being effective to engage said locating elementwhereby to-move said frame with said plate members,

and means at a subsequent station for fastening said 35 frame and saidstuds to said plate members.

8. Apparatus according to claim 7 wherein said second mentioned meansforms locating formations on both of said plate members,

9. Apparatus according to claim 8 wherein said locating formationscomprise semi-cylindrical notches in said plate members, and

said locating elements comprise semi-cylindrical projections adapted tofit in said notches.

10. Apparatus according to claim 9 wherein said locating elements restagainst said plate members and drop into said notches under theinfluence of gravity.

11. Apparatus for forming a building wall panel having spaced platemembers,

at least one sub-assembly frame having side ends and extending betweensaid plate members, and through studs-extending between said platemembers which comprises means for moving said plate members end-wise,

at least one of said plate members having 'a locating formation thereon,

said locating formation being located at the center for said frame,

means for yieldably maintaining said frame stationary intermediate saidplate member;

at least one locating element extending from said frame centrally ofsaid side ends of said frame, said locating formation being effective toengage sa1d locating element whereby to move said frame with said platemembers, and

means for thereafter fastening said frame and said studs to said platemembers.

12. Apparatus according to claim 11 wherein said locating formationcomprises a semi-cylindrical notch in said one plate member,

and

said locating element comprises a semi-cylindrical projection adapted tofit in said notch.

13. Apparatus according to claim 12 comprising a second semi-cylindricalnotch in the other of said plate members and aligned with said firstmentioned notch, and

a second semi-cylindrical projection on said frame and aligned with saidfirst mentioned projection,

said second projection being adopted to fit in said second notch.

14. Apparatus according to claim 11 wherein said locating elementcomprises a semi-cylindrical shell having a semi-circular flange at oneend thereof, and

means fastening said flange to said frame.

1. The method of forming a building wall panel having spaced platemembers, at least one sub-assembly frame extending between said platemembers, and through studs extending between said plate members whichcomprises forming said sub-assembly frame, forming first locating meanson at least one of the top and bottom ends of said frame and centrallyof the side ends of said frame, forming second locating means on atleast one of said plate members at the center for said frame, placingsaid frame intermediate said plate members, moving said plate membersendwise relative to said frame whereby to cause said first locatingmeans to engage said second locating means, thereafter fastening saidframe to said plate members, and fastening said studs to said platemembers.
 2. The method according to claim 1 comprising forming saidfirst locating means on both said top and bottom ends of said frame andforming said second locating means on both of said plate members.
 3. Themethod of forming a building wall panel having spaced plate members, atleast one sub-assembly frame extending between said plate members, andthrough studs extending between said plate members which comprisesforming said sub-assembly frame, forming first locating means on the topand bottom ends of said frame and centrally of the side ends of saidframe, forming second locating means on said plate members at the centerfor said frame, placing said frame intermediate said plate members,moving said plate members endwise relative to said frame whereby tocause said first locating means to engage said second locating means andto move said frame to a fastening station, and fastening said frame andsaid studs to said plate members at said fastening station.
 4. Themethod according to claim 3 comprising moving said plate members endwiseat a continuous rate of speed.
 5. The method of forming a building wallpanel having spaced plate members, at least one sub-assembly frameextending between said plate members, and through studs extendingbetween said plate members which comprises pre-forming said sub-assemblyframe, forming outwardly extending locating elements on the top andbottom ends of said frame and centrally of the side ends of said frame,forming locating notches in said plate member at the center for saidframe, placing said frame intermediate said plate members with saidlocating element resting on said plate members under the influence ofgravity, moving said plate members endwise relative to said framewhereby to enable said locating elements to drop into said locatingnotches and to cause said plate members to move said frame to afastening station, and fastening said frame and said studs to said platemembers at said fastening station.
 6. The method forming a building wallpanel having spaced plate members, at least one sub-assembly frameextending between said plate members, and through studs extendingbetween said plate members which comprises pre-forming said sub-assemblyframe, forming outwardly and co-axially extending semi-cylindricallocating elements on the top and bottom ends of said frame with the axesof said elements extending midway between the side ends of said frame,forming co-axially extending semi-cylindrical notches in said platemembers with the axes of said notches extending coincident with thecenter for said frame, placing said frame intermediate said platemembers with saiD locating elements resting on said plate members underthe influence of gravity, moving said plate members endwise relative tosaid frame whereby to enable said locating elements to drop into saidnotches and to cam said plate move said frame to a fastening station,spacing said studs along said plate members, and fastening said frameand said studs to said plate members at said fastening station. 7.Apparatus for forming a building wall panel having spaced plate members,at least one sub-assembly frame extending between said plate members andthrough studs extending between said plate members which comprises meansfor moving said plate members endwise successively through a pluralityof stations, means at one of said stations for forming a locatingformation on at least one of said plate members, said locating formationbeing located at the center for said frame, means at a subsequentstation for yieldably maintaining said frame stationary intermediatesaid plate members, said frame having at least one locating elementextending therefrom centrally of the side ends of said frame, saidlocating formation being effective to engage said locating elementwhereby to move said frame with said plate members, and means at asubsequent station for fastening said frame and said studs to said platemembers.
 8. Apparatus according to claim 7 wherein said second mentionedmeans forms locating formations on both of said plate members, and saidframe has locating elements extending from the top and bottom endsthereof and engageable with respective ones of said locating formation.9. Apparatus according to claim 8 wherein said locating formationscomprise semi-cylindrical notches in said plate members, and saidlocating elements comprise semi-cylindrical projections adapted to fitin said notches.
 10. Apparatus according to claim 9 wherein saidlocating elements rest against said plate members and drop into saidnotches under the influence of gravity.
 11. Apparatus for forming abuilding wall panel having spaced plate members, at least onesub-assembly frame having side ends and extending between said platemembers, and through studs extending between said plate members whichcomprises means for moving said plate members end-wise, at least one ofsaid plate members having a locating formation thereon, said locatingformation being located at the center for said frame, means foryieldably maintaining said frame stationary intermediate said platemember; at least one locating element extending from said framecentrally of said side ends of said frame, said locating formation beingeffective to engage said locating element whereby to move said framewith said plate members, and means for thereafter fastening said frameand said studs to said plate members.
 12. Apparatus according to claim11 wherein said locating formation comprises a semi-cylindrical notch insaid one plate member, and said locating element comprises asemi-cylindrical projection adapted to fit in said notch.
 13. Apparatusaccording to claim 12 comprising a second semi-cylindrical notch in theother of said plate members and aligned with said first mentioned notch,and a second semi-cylindrical projection on said frame and aligned withsaid first mentioned projection, said second projection being adopted tofit in said second notch.
 14. Apparatus according to claim 11 whereinsaid locating element comprises a semi-cylindrical shell having asemi-circular flange at one end thereof, and means fastening said flangeto said frame.